Introduction to the numerical Simulation of Twin Screw extruders Ludovic 2D Twin-Screw numerical Simulation XimeX 3D General Purpose Numerical Simulation
Numerical Simulation Why? Simulate the Equipment to Understand the Process Understand the Process to Control the process Control the Process to control the Product Production New product time to market Optimisation Scale-Up Stability vs process parameters Re-Engineering of existing Production (REACH) Optimisation of the «Test & Trial» process Variability of raw products (recycling..) Research & Development Indeep analysis New products (bio based, Nano...) Universities A good alternative of real cases Provide understanding of the physics pedagogical
2 different approaches for different objectives Model The equations of the flow are hard coded for standard screws elements The Navier & Stockes are computed on a FEM domain. audience Engineering & production Research & development Target Dedicated TSE Computing Time 500 simulations / h Principle Stationnary TSE Single Screw BUSS Batch Mixers... <4 h to 4 Days> Transient
Ludovic XimeX Applications fields Many Products... Many Applications... Food Processing Croquettes, cereals... Polymers Compounds, plastics sheets Bio-polymers Compounds with fibers Pharmacy Tablets Cosmetics Lipsticks, rimmel Energy Propergol......
Preparation a 5 steps process... Your Process with Ludovic Extruder φ η Products Process Options Execute RPM T C Kg/h RPM T C Kg/h Slipping Effect, User's Results, melt computation, Expansion, Reactive Extrusion Local Execution or.net Execution
Features Setting Opened to all TSE 5 Tabs technology Physics Simple melt model vs Advanced Melt zone computation Power, Carreau, set of points rheology definition Reactive Extrusion (uncoupled vs coupled) Execution One Shot execution Sequence execution Comparative & statistical analysis Optimisation Module (on going) Ready for Neural Meta-Model
«One Shot» execution Access to Global System Energy Analysis Residence Time Distribution Temperature, Pressure, Shear Rate along the Screw Profile Mean residence time Dissipated energy (viscous dissipation - screw) equivalent to 47.00 % Specific energy (solid transport - screw) equivalent to 22.27 % Melting Energy (screw) equivalent to 9.45 % Dissipated energy (viscous dissipation - die) equivalent to 1.62 % 39.96 s 137.95 kwh/t 65.38 kwh/t 27.75 kwh/t 4.76 kwh/t Total conduction energy (screw + die) equivalent to 19.66 % Total material energy Total material energy (abs. value of conduction) 57.70 kwh/t Power engine Torque / shaft Conduction power Barrel Barrel Barrel Barrel Barrel Barrel Barrel Barrel Barrel 35.38 kw 1049.14 N.m 1 2 3 4 5 6 7 8 9 178.15 kwh/t 293.54 kwh/t 0.0000 0.0000 0.3511-0.3053-0.7251-1.2504-2.5920-1.7303-2.3297 kw kw kw kw kw kw kw kw kw
Reactive Extrusion Definition of a chemical reactor This is the Evolution law of reaction rate X as a function of temperature and residence time. In the coupled mode, Ludovic links the product viscosity evolution (as a function of de X) with the transformation rate Exemple of Applications Radical polymerization of Styrene Controlled degradation of Polypropylene Dynamic Vulcanization of thermoplastic elastomers Caprolactone Polymerization...
Comparative & Statistical analysis Compare wide number of simulations Trends Identification Process key parameters tracking Process Parameters / results correlation
«Sequence «Execution Automated experiment Control of the plan parameters Unlimited results recording Display of Results (2D, 3D) Results export to Excel 1681 «One Shot» Simulations Preparation 5 mn Execution 53mn Exemple of Applications Prediction of the Kneading elts wearness on the mixing efficiency Torque evolution as a function of the flow rate Optimisation of the Flow Rate / rotation Speed
ETUDE CAS 24% diminution sur le couple 12% diminution sur temps de sejour moyen
The Optimiser (on going) Based on a genetic algoritm methodology Unlimited degree of freedom in the parameters choice Multiple objectives -Min, Max, Reference Curve Contraints Ex Max power of the engine, Torque,Max beared temperature Ludovic provides the 5 best «candidates» on a population of 3000 «One Shot» Simulations Exemple of Applications Scale-Up Optimisation of the Screw performance (Mixing...) Ready for Neural Meta-Models Neural models produce real time optimisation models (forward & backward propogation) for operating domain analysis (in situ)
Applications Global Macroscopic Analysis Degradation temperature Limit shaft pressure Temperature, Pressure, stress over the global process Global Macroscopic Analysis Twin Screw inter mixing area Wear phenomenum analysis Coupling with «Strength of materials software» Maximum shear Rates computation Support for blade/screw design Die equilibrium Microscopic Analysis Distributive Mixing Dispersive Mixing
Exemple Pressure as a function of the staggering Angle
Microscopic analysis macroscopic Mechanical Computation numerical particles Computation Physical model for particle behavior { Diameter distribution length distribution... added function Particles Quantification of the Mixing Efficiency -Local Elongation -Entropy (Shannon, Reyni -Intensity of Segregation Physical Phenomenums Fibers Breaking Agglomerate erosion
Carbon agglomerate Diameter Evolution 6/7
Define the Initial position of the particles... 4/7
Animations...
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